Production Planning Visual Management and The Power of Appropriate Modelling Author: Greg Whitbread Date: October 2018 Email: Greg.Whitbread@ricgroup.net RIC land Line: +27 11 8870795 Cell: +27 83 288 1927
Planning “If you fail to plan, you are planning to fail” - Benjamin Franklin - Benjamin Franklin 2
Case Study – Maltings Plant Study The Plant Project Approach: Make Understand Adjustment The process Identify Monitor the Opportunity for Greatest response Improvement Implement Develop the the solution solution 3
Case Study – Maltings Plant Steep IN Steep OUT to Germination Germination to Kiln 4
Case Study – The Old Planning Tool 5
Case Study - Streamlining 6
Case Study – The New Planning Tool 7
Case Study – The Results (Increased Throughput) Planning Tool Went Live 8
Case Study – Additional Benefits (Reduces Vessel Occupancy) Planning Tool Went Live Desired Occupancy 9
Case Study - Additional Benefits (Reduces Vessel Occupancy) Planning Tool Went Live Desired Occupancy 10
Objectives of Production Planning 5 of the 7 Wastes of LEAN Manufacturing • Effective resource utilization • Coordination of all areas of the plant • Raw material planning • Reduce Waste! 11
EFFECTIVE Planning vs Planning Essential when developing an EFFECTIVE planning model: ? 1 UNDERSTAND THE SYSTEM YOU USE EFFECTIVE VISUAL WANT TO MODEL MANAGEMENT TECHNIQUES 6 2 5 BUILD IN ALLOW THE MODEL FLEXIBILITY TO RESPOND TO FEEDBACK 3 4 USE HIGH QUALITY REMOVE ANY INPUT DATA UNNECESSARY COMPLEXITY 12
Flexibility WHAT COULD CHANGE? Demand Customer Preference Legislation Seasonality Trends New Tech PRS Manufacturing Process 13
High Quality Inputs for High Quality Outputs ƒ( ) = 14
Remove Unnecessary Complexity Poka – Yoke Automate repetitive tasks Remove any stumbling blocks Streamline and declutter the decision making process Quick effective decision making 15
Visual Management and Ergonomics MAKE USE OF: Gant Charts Dashboards KPI Trackers Warnings 16
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Feedback Loops DO Put this plan into action PLAN Develop a plan that is realistic for your plant PROCESS CHECK Monitor and pay close attention to the systems behavior and response to the plan ACT Use the information you collect to make meaningful adjustments to the planning operation 18
Thank You 19
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